Download Code™ - Code R™ Service Manual

2012
Code™ - Code R™
Service Manual
GEN.0000000003528 Rev B
SRAM LLC WARRANTY
SRAM warrants its products to be free from defects in materials or workmanship for a period of two
years after original purchase. This warranty only applies to the original owner and is not transferable.
Claims under this warranty must be made through the retailer where the bicycle or the SRAM
component was purchased. Original proof of purchase is required.
This warranty statement gives the customer specific legal rights. The customer may also have other
rights which vary from state to state (USA), from province to province (Canada), and from country to
country elsewhere in the world.
To the extent that this warranty statement is inconsistent with the local law, this warranty shall be
deemed modified to be consistent with such law, under such local law, certain disclaimers and
limitations of this warranty statement may apply to the customer. For example, some states in the
United States of America, as well as some governments outside of the United States (including
provinces in Canada) may:
a. Preclude the disclaimers and limitations of this warranty statement from limiting the statutory rights of
the consumer (e.g. United Kingdom).
b. Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations.
To the extent allowed by local law, except for the obligations specifically set forth in this warranty
statement, in no event shall SRAM or its third-party suppliers be liable for direct, indirect, special,
incidental, or consequential damages.
· This warranty does not apply to products that have been incorrectly installed and/or adjusted
according to the respective SRAM technical installation manual. The SRAM installation manuals can be
found online at www.sram.com, www.rockshox.com, www.avidbike.com, www. truvativ.com, or
www.zipp.com.
· This warranty does not apply when the product has been modified.
· This warranty does not apply when the serial number or production code has been deliberately altered,
defaced or removed.
· This warranty does not apply to damage to the product caused by a crash, impact, abuse of the product,
non-compliance with manufacturer’s specifications of usage or any other circumstances in which the
product has been subjected to forces or loads beyond its design.
· This warranty does not apply to normal wear and tear. Wear and tear parts are subject to damage as a
result of normal use, failure to service according to SRAM recommendations and/or riding or installation
in conditions or applications other than recommended.
Wear and tear parts are identified as:
Dust seals/Bushings/Air sealing o-rings/Glide rings/Rubber moving parts/Foam rings/Rear shock
mounting hardware and main seals/Stripped threads and bolts (aluminum,titanium, magnesium or steel)/
Upper tubes (stanchions)/Brake sleeves/Brake pads/Chains/Sprockets/Cassettes/Shifter and brake
cables (inner and outer)/Handlebar grips/Shifter grips/Jockey wheels/Disc brake rotors/Wheel braking
surfaces/Bottom out pads/Bearings/Bearing Races/Pawls/Transmission gears/Spokes/Free hubs/
Aero bar pads/Corrosion/Tools
· This warranty shall not cover damages caused by the use of parts of different manufacturers.
· This warranty shall not cover damages caused by the use of parts that are not compatible, suitable and/
or authorized by SRAM for use with SRAM components.
· This warranty shall not cover damages resulting from commercial (rental) use.
AVID BRAKE SERVICE
We recommend that you have your Avid brakes serviced by a qualified bicycle mechanic. Servicing Avid
brakes requires knowledge of brake components as well as the special tools and fluids used for service.
This publication includes trademarks and registered trademarks of SRAM Corporation designated by the symbols ™ and ®, respectively.
Copyright © SRAM LLC 2011
For exploded diagram and part number information, please refer to the Spare Parts Catalog available on our web site at www.sram.com.
For order information, please contact your local SRAM distributor or dealer.
Information contained in this publication is subject to change at any time without prior notice. For the latest technical information, please visit our website at www.sram.com.
Your product‘s appearance may differ from the pictures/diagrams contained in this catalog.
Product names used in this document may be trademarks or registered trademarks of others.
2

TABLE OF CONTENTS
CODE BRAKE LEVER OVERHAUL............................................................................................................................................ 5
PARTS AND TOOLS NEEDED FOR SERVICE:.................................................................................................................................................................. 5
CODE R BRAKE LEVER OVERHAUL........................................................................................................................................17
PARTS AND TOOLS NEEDED FOR SERVICE:................................................................................................................................................................. 17
CODE BRAKE CALIPER OVERHAUL...................................................................................................................................... 25
PARTS AND TOOLS NEEDED FOR SERVICE:................................................................................................................................................................25
AVID BRAKE HOSE LENGTH ADJUSTMENT.........................................................................................................................30
PARTS AND TOOLS NEEDED FOR SERVICE:............................................................................................................................................................... 30
AVID BRAKE BLEED PROCEDURE.........................................................................................................................................34
PARTS AND TOOLS NEEDED FOR SERVICE:................................................................................................................................................................34
DISC BRAKE PAD INSTALLATION INSTRUCTIONS............................................................................................................ 40
DISC BRAKE PAD AND ROTOR BED-IN PROCEDURE........................................................................................................ 41
3

SAFETY FIRST!
At SRAM, we care about YOU. Please, always wear your safety
glasses and protective gloves when servicing your
componentry.
Protect yourself! Wear your safety gear!
Important: Your parts may look different from those illustrated.
CODE BRAKE LEVER OVERHAUL
Avid brake lever assemblies need to be serviced periodically to optimize braking function. If brake fluid is leaking from any area
of the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 5.1 or 4 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake was
damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly. Inspection
and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake function.
WA R N I N G :
• Avid highly recommends the use of nitrile gloves when handling DOT fluids.
• DOT fluids will damage painted surfaces! If any fluid comes in contact with a painted surface (i.e. your frame) or printing
on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. Removal of paint and/or printing by DOT
fluid is not covered under warranty!
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
• For best results, use only Avid High-Performance 5.1 DOT Fluid. If Avid fluid is not available, only use DOT 5.1 or 4 fluid. Do not use mineral oil or DOT 5 fluid.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
PARTS AND TOOLS NEEDED FOR SERVICE:
5
• Safety glasses
• 4 mm hex bit socket
• Nitrile gloves
• 8 mm flare nut crowfoot
• Needle-nose pliers
• 8 mm flare nut wrench
• Long snap ring pliers
• 11 mm open end wrench
• Oil pan
• 2 mm hex
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid, or Avid
DOT Grease or DOT 5.1 or 4 compatible grease
• Two 4 mm hex wrenches
• 5 mm ferrule
• Isopropyl alcohol
• Torque wrench
• Clean, lint-free rag
• Bench vise or 10 mm open end wrench
Code brake lever overhaul
EXPLODED VIEW - CODE BRAKE LEVER ASSEMBLY
A
B
F
6
C
G
D
H
E
I
J
A. LEVER BODY
F. PISTON/BLADDER ASSEMBLY
B. LEVER PIVOT SHOULDER BOLT
G. SNAP RING
C. LEVER PIVOT SLEEVE BOLT
H. PUSHROD/SPRING ASSEMBLY
D. CAM COUPLER
I. CAM
E. LEVER BLADE
J. LEVER SPRING
(SHOWN REMOVED)
Code brake lever overhaul
1
Remove the brake lever from the handlebar.
Use a 4 mm hex to remove the brake clamp bolts from
the clamp.
Pull the hose boot off the compression nut and slide it
down the hose.
If dirty, clean the levers with alcohol and a clean rag.
4 mm
2
Use an 11 mm open end wrench to hold the hose stop in place
and use an 8 mm flare nut wrench to unthread the hose
compression nut. Pull the brake hose and compression fitting
from the brake lever body.
8 mm
7
11 mm
Code brake lever overhaul
3
Allow any brake fluid to drain into a container. Hold the lever
assembly over the container and squeeze the lever to pump
any brake fluid from inside the lever assembly.
If the system has been contaminated with the wrong fluid,
you will need to flush all the parts with soapy water, rinse,
and allow to dry prior to rebuilding. You will also need to
install all new seals and a new hose.
4
Use two 4 mm hex wrenches to remove the lever pivot
shoulder bolt and the lever pivot sleeve bolt.
You may need to push the shoulder bolt out
with the 4 mm hex or similar tool.
4 mm
4mm
4 mm
8
Code brake lever overhaul
5
Rotate the lever and cam assembly toward the clamp. Remove
the lever blade and lever spring from the cam.
6
Slide a 4 mm hex through the bearing in the cam and use the
hex to pull the cam off the end of the pushrod.
4 mm
9
Code brake lever overhaul
7
Use needle-nose pliers to remove the cam coupler from the
pushrod.
8
Use needle-nose pliers to forcefully pull on the pushrod to
remove the pushrod and spring from the piston/bladder
assembly.
9
Clamp a 2 mm hex into a vise with the long end extending
upward. Install the lever body onto the hex and insert the hex
into the hole located in the fluid flow port.
Place a clean rag under the lever body to wipe up any fluid
that may spill out.
2 mm
10
Code brake lever overhaul
long snap ring pliers to compress the snap ring. Then
10 Use
apply downward pressure to the lever body and use the pliers
to remove the snap ring in the lever body along with the
piston/bladder assembly. Remove the lever body from the hex.
The piston/bladder assembly is attached to the snap ring.
11
Replace the entire piston/bladder assembly with a new
assembly. Lubricate the new assembly by dipping it into Avid
High-Performance 5.1 DOT Fluid.
You can also use Avid DOT Grease, or DOT 5.1
or 4 compatible grease, as a lubricant.
12
Use long snap ring pliers to push the piston/bladder assembly
into the lever body, and secure the snap ring in its groove.
You can also use a long 10 mm socket against the snap
ring to push the assembly into the lever body.
If you push the snap ring past its groove, you can use the
2 mm hex in the vise to push on the assembly from inside the
fluid flow port, which will seat the snap ring into the groove.
11
Code brake lever overhaul
13
Install the lever body onto the 2 mm hex in the vise and insert
the hex into the hole located in the fluid flow port.
Use needle-nose pliers to re-install the pushrod
into the piston until you hear a click, indicating
the pushrod is seated in the piston.
2 mm
12
Code brake lever overhaul
Use needle-nose pliers to press the cam coupler onto the end
14 of
the pushrod. You will hear a click when the end of the
pushrod is seated inside the coupler.
Position the opening in the cam coupler so that it
faces toward the lever pivot.
Insert a leg of the lever spring into the hole on the lever cam.
15 Make
sure the spring makes contact with the inside of the
cam.
13
Code brake lever overhaul
Reinstall the lever blade onto the cam and lever spring. Insert
16 the
exposed spring leg into the hole on the lever blade.
Use your thumb to compress the spring between the
cam and the lever blade and align the pivot holes.
Insert a 5 mm cable ferrule as a tool to hold the cam and lever
blade together as you install the assembly into the lever body.
14
Code brake lever overhaul
17
18
Re-install the lever blade. Position the pocket in the cam over
the cam coupler. Slide the lever blade and cam straight into
the lever body until you hear a click, indicating the pushrod is
seated in the cam coupler.
Align the holes in the lever blade and lever body. Use a 4 mm
hex to re-install the lever pivot sleeve bolt into the aligned
holes, which will push out the ferrule tool used in step 16.
Be sure the ferrule tool is completely removed.
4 mm
19
Re-install the lever pivot shoulder bolt. Use a torque wrench
with a 4 mm hex bit socket to tighten the bolt to 2.0-2.5 N·m
(17-22 in-lb).
2 .0 - 2 . 5 N ∙ m ( 1 7- 2 2 i n - l b)
15
Code brake lever overhaul
the compression nut into the lever body by hand. Use
20 Thread
an 11 mm open end wrench to hold the hose stop in place,
then use a torque wrench with an 8 mm flare nut crowfoot to
tighten the compression nut to 4.9-5.4 N∙m (43-48 in-lb). Slide
the hose boot over the compression nut.
21
16
8 mm & 11 mm
4 . 9 - 5 . 4 N ∙ m ( 4 3 - 4 8 i n - l b)
4 mm
2 . 8 -3 . 4 N ∙ m ( 2 5 -3 0 i n - l b)
Re-install the brake lever onto the handlebar. Arrows on the
clamp must point up. Use a torque wrench with a 4 mm hex
bit socket to re-install the brake clamp bolt and tighten the
top bolt completely to 2.8-3.4 N·m (25-30 in-lb) so there is no
gap. Then tighten the bottom bolt to the same torque.
Code brake lever overhaul
CODE R BRAKE LEVER OVERHAUL
Avid brake lever assemblies need to be serviced periodically to optimize braking function. If brake fluid is leaking from any area
of the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake was filled with fluid
OTHER than DOT 5.1 or 4 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts may exist. If your brake was
damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as the housing assembly. Inspection
and/or replacement of these parts, due to any of the above situations, will be necessary to restore proper brake function.
WA R N I N G :
• Avid highly recommends the use of nitrile gloves when handling DOT fluids.
• DOT fluids will damage painted surfaces! If any fluid comes in contact with a painted surface (i.e. your frame) or printing
on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. Removal of paint and/or printing by DOT
fluid is not covered under warranty!
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
• For best results, use only Avid High-Performance 5.1 DOT Fluid. If Avid fluid is not available, only use DOT 5.1 or 4 fluid. Do not use mineral oil or DOT 5 fluid.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
PARTS AND TOOLS NEEDED FOR SERVICE:
• Safety glasses
• T25 TORX bit socket
• Nitrile gloves
• 8 mm flare nut crowfoot
• T25 TORX®
• 8 mm flare nut wrench
• Rubber mallet
• 11 mm open end wrench
• Long snap ring pliers
• 2, 2.5, 4, and 5 mm hex wrenches
• Oil pan
• Bench vise or 10 mm open end wrench
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid, or Avid
DOT Grease or DOT 5.1 or 4 compatible grease
• Isopropyl alcohol
• Clean, lint-free rag
• Torque wrench
17
code r brake lever overhaul
EXPLODED VIEW - CODE R BRAKE LEVER ASSEMBLY
B
A
F
18
G
C
E
D
H
I
J
A. LEVER BODY
E. LEVER BLADE
I. DOWEL
B. PIVOT BUSHINGS
F. PIVOT PIN
J. PUSHROD SLEEVE
C. PISTON/BLADDER/PUSHROD ASSEMBLY
G. PIVOT CLIP
D. REACH ADJUST KNOB
H. SNAP RING
(SHOWN REMOVED)
code r brake lever overhaul
1
Use a T25 TORX® to remove the brake clamp bolt from the
discrete clamp, MMX, or XLoc (XLoc will first require the
removal of the XX shifter). Remove the brake lever from the
handlebar. Pull the hose boot off the compression nut and slide
it down the hose.
If dirty, clean the levers with alcohol and a clean rag.
T25
2
Use an 11 mm open end wrench to hold the hose stop in place
and use an 8 mm flare nut wrench to unthread the hose
compression nut. Pull the brake hose and compression fitting
from the brake lever body.
8 mm 11 mm
19
code r brake lever overhaul
3
Allow any brake fluid to drain into a container. Hold the lever
assembly over the container and squeeze the lever to pump
any brake fluid from inside the lever assembly.
If the system has been contaminated with the wrong fluid,
you will need to flush all the parts with soapy water, rinse,
and allow to dry prior to rebuilding. You will also need to
install all new seals and a new hose.
4
Remove the pivot pin. Open a vise 1/2 inch and place a clean
rag over the jaws of the vise.
Position the pivot pin over the opening of the vise. Use a
rubber mallet to gently tap a 5 mm hex against the pivot pin.
Remove the hex and pivot pin from the brake lever.
The pivot bushings, pivot clip, and dowel may fall out of
the lever blade, this is ok. Set them aside on a clean rag.
5 mm
5
20
Turn the reach adjust knob counter-clockwise by hand to
remove the lever from the pushrod.
code r brake lever overhaul
6
To replace a damaged or lost reach adjust knob assembly:
Clamp a 4 mm hex into a vise with the long end extending
upward. Install the end of the sleeve onto the 4 mm hex.
Use a 2.5 mm hex to remove the reach stop screw, then remove
the reach knob, spring, cross dowel, and blade from the sleeve.
Install the new cross dowel into the lever blade and slide
the sleeve through the recessed side of the dowel.
Slide the new reach knob, followed by
the spring, onto the sleeve.
Clamp a 4 mm hex into a vise with the long end extending
upward. Install the end of the sleeve onto the 4 mm hex.
Use a 2.5 mm hex to install and tighten the reach
stop screw to 0.5-0.7 N·m (4-6 in-lb).
4 mm2.5 mm
Remove the reach adjust/blade assembly from the 4 mm hex.
4 mm
7
2.5 mm
Clamp a 2 mm hex into a vise with the long end extending
upward. Install the lever body onto the hex and insert the hex
into the hole located in the fluid flow port.
Place a clean rag under the lever body to
wipe up any fluid that may spill out.
2 mm
21
code r brake lever overhaul
8
Use long snap ring pliers to compress the snap ring. Then
apply downward pressure to the lever body and use the pliers
to remove the snap ring in the lever body along with the
piston/bladder assembly. Remove the lever body from the hex.
The piston/bladder assembly is attached to the snap ring.
CAUTION
Eye Hazard: Do not look directly into the lever body
while performing this step. The internal piston/
spring assembly is preloaded and will come out of
the lever body quickly. Wear safety glasses.
9
Replace the entire piston/bladder assembly with a new
assembly. Lubricate the assembly by dipping it into Avid
High-Performance 5.1 DOT Fluid.
You can also use Avid DOT Grease, or DOT 5.1
or 4 compatible grease, as a lubricant.
the snap ring on the retainer of the piston, with the
10 Position
clocked portion of the retainer seated between the two
centering tabs of the snap ring. Orient the snap ring eyelets
away from the lever blade opening.
22
code r brake lever overhaul
11
Use long snap ring pliers to push the piston/bladder assembly
into the lever body, and secure the snap ring in its groove.
You can also use a long 10 mm socket against the snap
ring to push the assembly into the lever body.
If you push the snap ring past its groove, you can use the
2 mm hex in the vise to push on the assembly from inside the
fluid flow port, which will seat the snap ring into the groove.
23
12
Insert a pivot bushing into each side of the lever body.
13
Align the pushrod sleeve and the pushrod. Turn the reach
adjust knob clockwise by hand to thread it onto the pushrod.
code r brake lever overhaul
the pivot pin. Confirm that the pivot bushings are still
14 Re-install
in place. Insert the pivot clip into lever blade and align it with
the
the
the
the
holes in the lever body and lever blade. Align the holes in
lever body, both bushings and the lever blade. Gently tap
pivot pin into place with a rubber mallet until it is flush with
lever body.
The lever blade action may feel sluggish following
installation of the pivot pin. To improve the feel, mount
the brake lever onto the handlebar, hold the lever blade
between your thumb and forefinger, then gently flex the
lever blade from side to side. Check the lever pivot action.
Repeat this process until the lever pivot action feels
smooth. Be careful not to flex the lever too far at any time,
otherwise damage to the lever blade or body could occur.
15
Thread the compression nut into the lever body by hand. Use
an 11 mm open end wrench to hold the hose stop in place, then
use a torque wrench with an 8 mm flare nut crowfoot to
tighten the compression nut to 4.9-5.4 N∙m (43-48 in-lb). Slide
the hose boot over the compression nut.
8 mm & 11 mm
16
4 . 9 - 5 . 4 N ∙ m ( 4 3 - 4 8 i n - l b)
Re-install the brake lever into the discrete clamp, MMX, or
XLoc. Use a torque wrench with a T25 TORX® bit socket to
re-install the brake clamp bolt into the discrete clamp, MMX, or
XLoc and tighten to 5-6 N∙m (44-52 in-lb).
T 2 5 24
5 - 6 N ∙ m ( 4 4 - 52 i n - l b)
code r brake lever overhaul
CODE BRAKE CALIPER OVERHAUL
Avid brake lever assemblies need to be serviced periodically in order to optimize braking function. If brake fluid is leaking
from any area of the brake lever assembly, there may be damage or wear and tear to the internal moving parts. If your brake
was filled with fluid OTHER than DOT 5.1 or 4 (such as mineral oil or DOT 5), damage to all rubber and plastic internal parts
may exist. If your brake was damaged in a crash, there may be damage to the lever blade and pushrod assemblies, as well as
the housing assembly. Inspection and/or replacement of these parts, due to any of the above situations, will be necessary to
restore proper brake function.
WA R N I N G :
• Avid highly recommends the use of rubber gloves when handling DOT fluids.
• DOT fluids will damage painted surfaces! If any fluid comes in contact with a painted surface (i.e. your frame) or printing
on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. Removal of paint and/or printing by DOT
fluid is not covered under warranty!
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
• For best results, use only Avid High-Performance 5.1 DOT Fluid. If Avid fluid is not available, only use DOT 5.1 or 4 fluid. Do not use mineral oil or DOT 5 fluid.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
PARTS AND TOOLS NEEDED FOR SERVICE:
• Safety glasses
• Torque wrench
• Nitrile gloves
• 5 mm hex bit socket
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid, or Avid
DOT Grease or DOT 5.1 or 4 compatible grease
• 2.5 and 5 mm hex
• Oil pan
• Flat blade screwdriver
• Sharp pick
• Clean, lint-free rags
• Isopropyl alcohol
• Air compressor with blow gun chuck
TROUBLESHOOTING
‘Sticky’ or slow brake pad return feel
Before completely disassembling your caliper, it’s worth trying to loosen the sticky piston. Try the following:
1.
Clamp the bicycle in a bicycle work stand.
2.
Spin the affected wheel. Lightly squeeze the brake lever and watch the brake pads when the lever is released.
3.
Determine which side of the caliper has a slow returning brake piston.
4.
Remove the caliper from the bicycle. If you have a caliper mounting bracket, remove the bracket with the caliper attached.
5.
Remove e-clip from the guide pin groove on top of the caliper. Use a 2.5 mm hex to remove the guide pin from the caliper.
6.
Remove both brake pads and h-spring.
7.
Use a 10 mm box wrench to press the working piston into caliper body.
8.
While continuing to hold the piston inside the caliper body, squeeze the brake lever slowly to move the sticky piston inward.
Press the piston back into the caliper again.
9.
Repeat these steps to correct caliper piston inner o-ring position.
10. Both pistons should now be moving freely. Re-install the spring pad clip, h-spring, and pads into the caliper. If there is no
improvement, continue with caliper service.
11. Re-install the caliper (or mounting bracket with attached caliper) on the bicycle. You may need to re-center the caliper to the
rotor. If you removed the caliper without an adapter, or removed it from the adapter, it will need to be re-centered. Spin the
wheel and check brake function.
25
Code brake caliper overhaul
1
Use a 5 mm hex to remove the brake caliper from the fork or
frame and remove the caliper mounting bracket and hardware
from the caliper. Set aside in the correct order (not pictured).
2
Remove the e-clip from the guide pin groove on top of the
caliper. Use a 2.5 mm hex to remove the guide pin from the
caliper.
3
Pull and remove both brake pads and h-spring.
2.5 mm
If the total thickness of the backing plate and pad friction
material is less than 3 mm, the brake pads need to be replaced.
Click here for detailed brake pad removal instructions
4
Use a 5 mm hex to remove the caliper body bolts.
Brake fluid will leak, so hold the caliper over a container
to catch the fluid.
5 mm
26
Code brake caliper overhaul
5
Separate the caliper body halves and open the caliper
assembly. Remove the banjo from the caliper.
6
Caliper Piston Removal:
Insert an air compressor chuck nozzle into the
hole of one of the caliper body halves.
Cover the pistons with at least two rags. Point
the caliper pistons and rags into your hand.
Squeeze the air chuck and force air into the hole in the
caliper half. The compressed air will unseat the pistons
from the caliper. Remove the pistons from the caliper.
Insert chuck nozzle
WA R N I N G :
Point the caliper in a safe direction. Use two rags to
prevent the pistons from causing injury or becoming lost.
Repeat this process for the other caliper body half.
If both pistons do not unseat simultaneously, cover
the open piston bore with a piece of inner tube and
use the air chuck to unseat the second piston.
7
Remove the square-edge o-rings from inside each caliper body
half with a sharp pick. Lubricate the new square-edge o-rings
with Avid High-Performance 5.1 DOT Fluid and install them
inside each caliper body half.
Do not scratch the o-ring gland with the pick.
You can also use Avid DOT Grease, or DOT 5.1
or 4 compatible grease, as a lubricant.
27
Code brake caliper overhaul
8
Inspect the caliper pistons for damage and replace if
necessary. Re-install the caliper brake pistons into each half of
the caliper body.
9
Use a sharp pick to remove the o-ring on the inside each
caliper half. Lubricate the new o-rings with Avid DOT Grease
and install them inside each caliper body half.
Do not scratch the o-ring gland with the pick.
You can also use DOT 5.1 or 4 compatible grease as a lubricant.
Make sure the o-ring is seated in the recessed gland.
10
Re-assemble the caliper halves. Loosely thread the caliper
body bolts clockwise by hand. Re-install the banjo between
the caliper halves.
11
Use a torque wrench with a 5 mm hex bit socket to tighten the
caliper body bolts to 8.5-10 N·m (75-90 in-lb).
5 mm
28
8.5-10 N∙m (75-90 i n - l b)
Code brake caliper overhaul
12
Insert the Bleed Block into the caliper in place of the brake
pads.
You will need to bleed your brakes before re-installing
the brake pads.
13
Clean the assembled caliper with alcohol and a clean rag to
remove any brake fluid.
14
Visually check your work. Inspect the banjo for any protruding o-rings. If there are any o-rings that are ‘squeezed’ beyond the
outside edges of the banjo or bolt, remove and replace the o-rings, and then repeat the installation process.
Overhauling the caliper introduces a small amount of air into the system, so at this point it is necessary to bleed the brakes for
optimal performance. See the section, “Avid Brake Bleed Procedure” for instructions.
29
Code brake caliper overhaul
AV I D B R A K E H O S E L E N G T H A DJ U S T M E N T
After completing the hose length adjustment, it will be necessary to bleed the brakes for optimal performance. See the section,
“Avid Brake Bleed Procedure” for instructions.
WA R N I N G :
• Avid highly recommends the use of nitrile gloves when handling DOT fluids.
• DOT fluids will damage painted surfaces! If any fluid comes in contact with a painted surface (i.e. your frame) or printing
on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. Removal of paint and/or printing by DOT
fluid is not covered under warranty!
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
• For best results, use only Avid High-Performance 5.1 DOT Fluid. If Avid fluid is not available, only use DOT 5.1 or 4 fluid. Do not use mineral oil or DOT 5 fluid.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
PARTS AND TOOLS NEEDED FOR SERVICE:
• Safety glasses
• Adjustable torque wrench
• Nitrile gloves
• 8 mm flare nut wrench
• Hydraulic hose cutters or very sharp cable housing cutters
• 11 mm open end wrench
• Avid DOT Grease or DOT 5.1 or 4 compatible grease
• T10 TORX®
• Isopropyl alcohol
• Clean, lint-free rag
• Avid Bleed Kit or Avid Professional Bleed Kit
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid
Compression fittings
TORX
Hose barbs
Syringes
Avid
High-Performance
DOT Fluid
Bleed Block
(actual bleed block
may differ)
Avid Bleed Kit Contents
30
avid brake hose length adjustment
1
Make sure the hoses are properly secured to the bicycle and
check the routing of each hose. Account for suspension
movement and be sure the handlebars can move freely by
turning the bars all the way from side to side.
2
Pull the hose boot away from the lever to access the
compression nut. If the boot sticks, carefully pry up a corner
with something that won’t harm it (like the end of a zip tie)
and spray isopropyl alcohol between the boot and the lever.
Work the alcohol in; the boot should loosen up and slide easily
down the hose.
3
For models with a compression nut and a hex hose stop: Use
an 11 mm open end wrench to hold the hose stop in place and
use an 8 mm flare nut wrench to unthread the compression
nut.
For models with a compression nut only: Use an 8 mm
flare nut wrench to unthread the compression nut.
Hex hose stop
Compression nut
Compression nut
4
Pull the hose from the lever. Be careful, DOT fluid will drip from
the hose. Try not to spill too much fluid because any fluid that
drips out will create bubbles that you’ll have to eliminate later.
Slide the nut down the hose and away from
the end where you’ll be cutting. Do not pull the
brake lever while the hose is removed.
31
avid brake hose length adjustment
5
Determine where you need to cut the hose by holding it up to
the lever in the position you like. Make sure to leave a gentle
bend in the hose with enough length to freely turn the bars all
the way from side to side. Double-check this measurement
because you can’t go back after you cut.
The groove in the lever nose marks the spot where
you’ll cut the hose. Cut the hose using hydraulic hose
cutters or very sharp cable housing cutters.
Measure twice, cut once!
6
Apply Avid DOT Grease to the threads of a new hose barb, the
compression fitting outer surfaces and compression nut
threads.
While holding the hose firmly, use a T10 TORX® to thread
the hose barb into the end of the hose until it is flush.
Slide a new compression fitting over the end
of the hose with the new hose barb.
7
32
Push the hose firmly into the lever until it stops.
While holding the hose in place, slide the compression
fitting and compression nut up to the lever or hose stop.
avid brake hose length adjustment
8
For models with a compression nut and a hex hose stop:
While continuing to push the hose into the hose stop, use an
11 mm open end wrench to hold the hose stop in place and use
an 8 mm flare nut wrench to tighten the compression nut to
the proper torque.
For models with a compression nut only: While continuing
to push the hose into the lever body, use an 8 mm flare nut
wrench to tighten the compression nut to the proper torque.
· If your compression fitting is alloy, tighten to 5 N·m (47 in-lb).
· If your compression fitting is steel, tighten to 7.8 N·m (70 in-lb)
9
Slide the boot back into place.
Cutting the hose introduces a small amount of air into the system, so at this point it is necessary to bleed the brakes for optimal
performance. See the next section, “ Avid Brake Bleed Procedure” for instructions.
33
avid brake hose length adjustment
AV I D B R A K E B L E E D P R O C E D U R E
Avid brakes are the most powerful and precise hydraulic brakes on the market. A key reason behind this is the ability to optimize
brake performance with a perfect bleed. The goal of bleeding is to remove any air that is trapped in the hose, caliper, or lever. Air
trapped in a hydraulic brake system degrades the performance of the brake. The following instructions will walk you through our
simple bleed procedure.
Avid brakes come with hoses attached and bled. If you don’t need to change the hose length, you do not need to bleed the
system prior to installation.
Supplemental video instruction is available at www.sram.com/en/service.
WA R N I N G :
• Avid highly recommends the use of nitrile gloves when handling DOT fluids.
• DOT fluids will damage painted surfaces! If any fluid comes in contact with a painted surface (i.e. your frame) or printing
on the brakes, wipe it off immediately and clean with isopropyl alcohol or water. Removal of paint and/or printing by DOT
fluid is not covered under warranty!
• Do not allow any brake fluid to come in contact with the brake pads. If this occurs, the pads are contaminated and must be
replaced.
• For best results, use only Avid High-Performance 5.1 DOT Fluid. If Avid fluid is not available, only use DOT 5.1 or 4 fluid. Do not use mineral oil or DOT 5 fluid.
• Used DOT fluid should be recycled or disposed of in accordance to local and federal regulations.
• Never pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
PARTS AND TOOLS NEEDED FOR SERVICE:
• Safety glasses
• Avid Bleed Block
• Nitrile gloves
• 2.5 and 4 mm hex wrenches
• T10 TORX®
• Sharp pick
• Isopropyl alcohol
• Clean, lint-free rag
• Avid Bleed Kit or Avid Professional Bleed Kit
• Avid High-Performance 5.1 DOT Fluid or DOT 4 Fluid
Compression fittings
TORX
Hose barbs
Syringes
Avid
High-Performance
DOT Fluid
Bleed Block
(actual bleed block
may differ)
Avid Bleed Kit Contents
34
avid brake bleed procedure
When bleeding Avid brakes, keep in mind that you are simply forcing air bubbles out of the system. We recommend that you
bleed your brakes at least once a year to ensure optimal performance. If you ride frequently or in aggressive terrain, you should
bleed your brakes more often.
When bleeding brakes, you may notice discoloration of the old fluid as it exits the system into the syringe at the lever. If the
fluid is severely discolored, this indicates that the fluid is very old. In this case, bleeding the system twice in order to completely
remove the old fluid is recommended.
1
Fill one syringe 1/2 full with Avid High-Performance 5.1 DOT
Fluid and fill the other syringe 1/4 full.
Hold each syringe with the tip pointed up and tap
the side of the syringe with your finger to bring
any air bubbles to the top. Place a clean rag around
the tip and slowly push the air bubbles out of the
syringe. Close the hose clamp on each syringe.
2
De-gas the fluid in the 1/2 full syringe. Leave the hose clamp
shut and pull on the plunger. Bubbles will form in the brake fluid. While the
plunger is still pulled down, lightly tap the syringe to release
the bubbles sticking to the sides and the bottom so that they can rise to the top
of the fluid. When the bubbles stop forming and have all risen to the top, release
the plunger, open the clamp and carefully push the air out. Repeat several times.
You will not be able to remove all the bubbles.
3
Remove the wheel from your bike. Remove the brake pads and spreader clip from
the caliper and insert the appropriate Bleed Block. This will help prevent system
overfill and keep DOT fluid from contaminating your brake
pads.
Click here for detailed brake pad removal instructions
35
4
Use the T10 TORX® to remove the caliper bleed port screw
from the caliper body or banjo bolt
5
Make sure the fluid in the 1/2 full syringe is pushed all the way
to the tip (no air gap!), then thread into the caliper bleed port.
avid brake bleed procedure
6
For models with Contact Point Adjustment and a rotating
bleed port screw located on the contact point adjuster:
rotate the adjuster in the direction opposite the arrow until
it stops, then rotate the adjuster back just enough to place
the bleed screw at its highest point.
For models with Contact Point Adjustment and a fixed
bleed port screw: rotate the adjuster in the direction
opposite the arrow on the adjuster knob until it stops.
7
For models equipped with Reach Adjust, make sure the tip
of the lever blade is 75-80 mm from the centerline of the
handlebar. If the lever is too far out, it can make bleeding
the brake impossible.
75-80 mm
8
9
Use the T10 TORX® to remove the lever bleed port screw.
Make sure the fluid in the 1/4 full syringe is pushed all the way
to the tip (no air gap!), then thread into the lever bleed port.
It is not necessary to reposition the angle of the brake lever on
the handlebar. You may have a small amount of DOT fluid drip
from the bleed port screw, this is normal. Just have a clean rag
handy to wipe off any excess after the syringe is installed.
36
avid brake bleed procedure
10 Hold both syringes upright.
Gently push on the caliper syringe plunger to move
fluid from the caliper syringe into the lever syringe
until the lever syringe is increased to 1/2 full and
the caliper syringe is decreased to 1/4 full.
You should see bubbles form in the lever syringe.
11
Close the syringe clamp on the lever.
12
Pull the brake lever all the way to the bar with your finger and
hold it there until instructed to release the lever in a later step.
If you don’t want to hold the lever with your finger, have a friend
hold it or you can fasten it with a zip-tie or rubber band.
13
Pull out on the caliper syringe plunger to create a vacuum then
gently push in on the plunger to pressurize the system. Repeat
this procedure several times, until large bubbles stop coming out of
the caliper.
Do not pull the plunger past the end of the syringe.
37
avid brake bleed procedure
the large bubbles at the caliper have stopped, apply a
14 Once
small amount of pressure on the syringe plunger and slowly let
the pressure extend the brake lever you have been holding
with your finger. If you fastened the lever with a zip-tie or
rubber bands, remove these first but keep the lever pulled in
with your finger, then apply pressure on the syringe plunger.
You will feel the pressure at your finger on the lever, just let
the fluid extend the lever back to its original position.
15
Close the clamp on the caliper syringe, then remove the
syringe from the caliper and re-install the bleed port screw.
Use a clean rag to wipe off any excess DOT fluid that spills
out as you re-install the bleed port screw.
16
Open the syringe clamp on the lever.
17
Pull out on the lever syringe plunger to create a vacuum, then
gently push in on plunger to pressurize the system. Squeeze
and release the brake lever ten times, allowing the lever to snap back
to its starting position after squeezing (this helps break loose the bubbles).
Repeat this procedure of creating a vacuum at the syringe and
squeezing the brake lever ten times until large bubbles stop
coming out of the lever.
Do not pull out too hard on the plunger or you will suck air past the plunger
seal into the fluid and create more bubbles that you will have to eliminate.
38
avid brake bleed procedure
the large bubbles at the lever have stopped, apply a
18 Once
small amount of pressure on the syringe plunger then remove
the syringe and re-install the bleed port screw.
There will be a small amount of excess DOT fluid
that spills out as you remove the syringe and re-install the bleed port screw,
this is normal. be sure to wipe the fluid off the lever with a clean rag.
19
Spray isopropyl alcohol or water onto a clean rag and wipe off
the brake lever and caliper to remove any excess DOT fluid.
check your work. Inspect the banjo bolt and banjo for
20 Visually
any protruding o-rings. If there are any o-rings that are
‘squeezed’ beyond the outside edges of the banjo or bolt,
remove and replace the o-rings, and then repeat the
installation process.
21
Remove the Bleed Block from the caliper and re-install the
brake pads and spreader clip.
22
Reinstall your wheel according to the manufacturer’s
instructions.
WA R N I N G :
• Empty the syringes into a sealed container and dispose of the fluid properly. Remember, DOT fluid should be recycled or
disposed of in accordance to local and federal regulations.
• NEVER pour DOT fluid down a sewage or drainage system or into the ground or a body of water.
• Do not re-use this fluid.
• Do not leave the hose clamps closed, this will damage the clear tubing on the syringes.
23
39
You are almost ready to ride, but first it’s a good idea to test
your brakes. Pull on the lever extremely hard (as hard as you
can imagine yourself pulling the lever while you’re riding)
several times. Make sure to look around the compression nut
on the lever, and the banjo bolt on the caliper for any leaks.
Make one last check of all the bolts and fittings.If everything
checks out, YOU ARE READY TO RIDE!
avid brake bleed procedure
D I S C B R A K E PA D I N S TA L L AT I O N I N S T R U C T I O N S
1
2
Remove pad retainer bolt.
Start by removing the e-clip on the wheel side of the caliper,
then unthread the retainer bolt using a 2.5 mm hex.
Remove the retainer bolt all the way.
E-clip
Push the pistons back in.
Elixir calipers are self-adjusting, the pistons need to be pushed
back into the body to their original position before the new
pads can be installed. The safest way to do this is with the old
pads still in the caliper to protect the pistons. Place a flatblade screwdriver between the old pads, then carefully rock
it back and forth, pushing the pistons back into their bores.
0.6-0.9 N·m
(5-8 in-lb)
40
3
Remove the old pads.
4
Install the new pads and spreader.
5
Re-install the pad retainer bolt.
Grab the pad tabs and pull straight out.
Be sure the spreader clip is oriented to the pads as
shown. Align the hole in the spreader clip with the holes
in the pad tabs. Squeeze the pad and clip assembly
together, then insert into the caliper as a unit. Firmly
push until the assembly is seated into place.
Replace the pad retainer bolt, tighten to torque specifications,
and replace the e-clip on the wheel side of the caliper.
DISC BRAKE PAD INSTALLATION INSTRUCTIONS
DISC BRAKE PAD AND ROTOR BED-IN PROCEDURE
All new brake pads and rotors should be put through a wear-in process called ‘bed-in’. The bed-in procedure, which should be
performed prior to your first ride, ensures the most consistent and powerful braking feel along with the quietest braking in most
riding conditions. The bed-in process heats up the brake pads and rotors which deposits an even layer of brake pad material
(transfer layer) to the braking surface of the rotor. It this transfer layer that optimizes braking performance.
WA R N I N G :
The bed-in process requires you to perform heavy braking. You must be familiar with the power and operation of disc
brakes. Braking heavily when not familiar with the power and operation of disc brakes could cause you to lose control of
your bicycle, which could lead to a crash and could lead to serious injury and/or death. If you are unfamiliar with the power
and operation of disc brakes, you should have the bed-in process performed by a qualified bicycle mechanic.
I M P O R TA N T:
To safely achieve optimal results, remain seated on
the bike during the entire bed-in procedure.
1
Accelerate the bike to a moderate speed, then firmly apply the
brakes until you are at walking speed. Repeat approximately
twenty times.
2
Accelerate the bike to a faster speed. Then very firmly apply
the brakes until you are at walking speed. Repeat
approximately ten times.
I M P O R TA N T:
Do not lock up the wheels at any point during the bed-in procedure.
3
41
Allow the brakes to cool prior to any additional riding.
disc brake pad and rotor bed-in procedure
www.sram.com